This project is part of RTD 3 of the EU-project "Masmicro".
The object of Masmicro is to develop new knowledge on the manufacturing of miniature/micro-products, convert the knowledge into new technologies and facilities, and transfer this knowledge and these technologies to the industry.
RTD 3 deals with the design and construction of forming tools for miniature/micro- forming.
The purpose of the project is to design and develop a flexible tool system for cold forging micro-components.
The advantages of cold forging micro-components are the same as for conventional cold forging, namely the high production rate and the low material waste.
When transferring the technique of cold forging from macro- to micro-scale, size effect and change in friction are conditions that have to be considered. Furthermore the precision of the tool system is crucial owing to the low tolerances on the dimensions of micro-components.
The tool system is designed to have the ability to switch between the eight basic cold forging processes by quickly replacing a few parts.
A die has been made by using electrical discharge machining (EDM). Furthermore the making of a tool using electrodeposition has been examined, but this has not lead to the manufacturing of a tool yet. The manufacturing of the die by these methods is part of the Masmicro RTD 6.
To ensure the final geometry of the workpiece the tolerances of the billets has been examined.
For testing the tool system a c-program has been written to run the test press.
Testing of the final tool system has been done. It showed that the tool system can be used to cold forge micro-components. Further work has to be done to ensure that the tolerances of the components are maintained and a redesigning of the ejector system is needed.
To examine the profitability of cold forging versus machining, an economical estimate has been made.